Pressure-sensitive adhesives including expandable graphite

ABSTRACT

A building material comprising a substrate layer and a pressure-sensitive adhesive layer, where the pressure-sensitive adhesive layer includes expandable graphite.

This application is a continuation of U.S. application Ser. No.14/441,286, filed on May 7, 2015, which is the National Stage ofInternational Application No. PCT/US2013/068902, filed Nov. 7, 2013,which is a continuation of U.S. Pat. No. 8,968,853, filed on Mar. 14,2013, which claims the benefit of U.S. Provisional Application No.61/723,354, filed on Nov. 7, 2012; all of which are incorporated hereinby reference.

FIELD OF THE INVENTION

Embodiments of the present invention are directed towardpressure-sensitive adhesives that include expandable graphite. Theseadhesives are useful for adhering construction materials, such asroofing membranes, moisture, air and vapor barriers, and underlayments,to various substrates while providing the construction materials withimproved fire and/or flame-spread resistance.

BACKGROUND OF THE INVENTION

Pressure-sensitive adhesives are employed in building materials. Forexample, as disclosed in Statutory Invention Record H1,735, roofingmembranes, such as EPDM membranes, can be adhered to adjoining membranesor to a roof surface by an adhesive layer that is coated on theunderside of the roofing membrane. The adhesive layer disclosed in thisInvention Record includes a hydrogenated styrene-butadiene-styrene orhydrogenated styrene-isoprene-styrene block copolymer having apolystyrene content of from 20 to 40 percent by weight and an overallweight average molecular weight from 50,000 to 150,000, a polyphenyleneether resin having an intrinsic viscosity of less than 0.35 decilitersper gram or a high-softening point end-block reinforcing resin, and atackifying resin.

Similarly, U.S. Publication No. 2003/0219564 discloses a single-plyroofing membranes that include a water impermeable membrane, such as anEPDM membrane, and a pressure-sensitive, hot-melt adhesive adhered toone side of the membrane. A release liner may be secured to thepressure-sensitive, hot-melt adhesive opposite of the water impermeablemembrane.

There is a desire to improve the flame and fire resistance of buildingmaterials such as roofing membranes.

SUMMARY OF THE INVENTION

Embodiments of the invention provide a building material comprising asubstrate layer and a pressure-sensitive adhesive layer, where thepressure-sensitive adhesive layer includes expandable graphite.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a membrane according to one or moreembodiments of the present invention.

FIG. 2 is a cross-sectional view of a moisture barrier according to oneor more embodiments of the invention.

FIG. 3 is a cross-sectional view of an underlayment according to one ormore embodiments of the invention.

FIG. 4 is a cross-sectional view of a tape according to one or moreembodiments of the invention.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Embodiments of the present invention are based, at least in part, on thediscovery of a pressure-sensitive adhesive composition containingexpandable graphite. In one or more embodiments, the expandable graphiteis dispersed within the constituents of the pressure-sensitive adhesive;in other words, the pressure-sensitive adhesive forms a matrix in whichthe expandable graphite is dispersed. In other embodiments, theexpandable graphite is located within a region or layer within thepressure-sensitive adhesive where the expandable graphite isconcentrated. In yet other embodiments, the expandable graphite is bothdispersed within the pressure-sensitive adhesive and located within aconcentrate layer or region. In particular embodiments, thepressure-sensitive adhesive composition is mated to a building materialto provide a building material with increased flame and/or fireresistance while providing the building material with a mechanism forattachment. In one or more embodiments, the building material isadvantageously a roofing membrane, and the composition of the presentinvention can be used to form a fully-adhered roofing system havingimproved flame-spread and/or fire resistance. In other embodiments, thebuilding material is underlayment. In yet other embodiments, thebuilding material is a moisture, vapor or air barrier.

Pressure-Sensitive Adhesive Composition

Practice of the present invention is not necessarily limited by the typeof pressure-sensitive adhesive composition employed. In other words, theconstituents that form the adhesive composition in which the expandablegraphite is dispersed or otherwise located may include conventionalconstituents used to form pressure-sensitive adhesive compositions.Included among useful pressure-sensitive adhesives are holt-meltadhesives, which are flowable when heated to threshold temperatures, andsolvent-borne adhesives, which include those compositions where thesolids portion of the adhesive is dissolved or suspended in a solvent.

In one or more embodiments, the pressure-sensitive adhesive ischaracterized by a tack, as defined by the Standard Test Method for Tackof Pressure-Sensitive Adhesives by Rolling Ball (ASTM D3121-06), of lessthan 30 cm, in other embodiments less than 20 cm, and in otherembodiments less than 10 cm.

In one or more embodiments, the pressure-sensitive adhesive ischaracterized by providing a minimum peel strength, as defined by theStandard Test Method for Peel Adhesion of Pressure-Sensitive LabelStocks at 90° Angle (ASTM D6252/D6252M-98(2011)), of at least 0.1 pli,in other embodiments at least 0.3 pli, and in other embodiments at least0.5 pli.

In one or more embodiments, especially where the pressure-sensitiveadhesive is a hot-melt adhesive, the pressure-sensitive adhesivecomposition may be characterized as a solid at temperatures below 200°F. (93.3° C.), in other embodiments below 190° F. (87.8° C.), in otherembodiments below 180° F. (82.2° C.), and in other embodiments below170° F. (76.7° C.). In these or other embodiments, thepressure-sensitive adhesive composition is characterized as a fluidabove 200° F. (93.3° C.), in other embodiments above 250° F. (121° C.),in other embodiments above 300° F. (149° C.), and in other embodimentsabove 350° F. (177° C.).

Exemplary pressure-sensitive adhesive compositions that may be employedin practicing the present invention include those compositions basedupon acrylic polymers, butyl rubber, ethylene vinyl acetate, naturalrubber, nitrile rubber, silicone rubber, styrene block copolymers,ethylene-propylene-diene rubber, atatic poly-alpha olefins, and/or vinylether polymers. In combination with these base polymers, thepressure-sensitive adhesive compositions may include a variety ofcomplementary constituents such as, but not limited to, tackifyingresins, waxes, antioxidants, and plasticizers.

In particular embodiments, the pressure-sensitive adhesive compositionsof the present invention include polystyrene block copolymers. Theseblock copolymers include at least two types of blocks, which may bereferred to as A and B blocks, where the A blocks represent blocksderiving from the polymerization of at least one vinyl aromatic monomer(e.g., styrene) and the B blocks derive from the polymerization of atleast one conjugated diene monomer (e.g., butadiene). Exemplary vinylaromatic monomer includes styrene, p-methylstyrene, a-methylstyrene, andVinylnaphthalene. Examples of conjugated diene monomer include1,3-butadiene, isoprene, 1,3-pentadiene, 1,3-hexadiene,2,3-dimethyl-1,3-butadiene, 2-ethyl-1,3-butadiene,2-methyl-1,3-pentadiene, 3-methyl-1,3-pentadiene,4-methyl-1,3-pentadiene, and 2,4-hexadiene.

In particular embodiments, the block copolymers include at least two Ablocks and at least one B block. For example, the use of A-B-A blockcopolymers is specifically contemplated. In one or more embodiments, theB block may be hydrogenated. In one or more embodiments, the B block ischaracterized by at least 75 percent hydrogenation, in other embodimentsat least 85 percent hydrogenation, and in other embodiments at least 95percent hydrogenation, where the percent hydrogenation refers to thenumber of original double bonds within the block reduced byhydrogenation. For example, a polymer block that is 95 percenthydrogenated includes 5 percent of the original double bonds. In one ormore embodiments, the aromatic unsaturation within the A blocks ishydrogenated by less than 25 percent, in other embodiments less than 15percent, and in other embodiments less than 5 percent.

In one or more embodiments, each A block has an number average molecularweight of at least 2 kg/mole, in other embodiments at least 5 kg/mole,and in other embodiments at least 25 kg/mole. In these or otherembodiments, each A block has an number average molecular weight of lessthan 125 kg/mole, in other embodiments less than 75 kg/mole, and inother embodiments less than 50 kg/mole.

In one or more embodiments, each B block has a number average molecularweight of at least 10 kg/mole, in other embodiments at least 30 kg/mole,and in other embodiments at least 50 kg/mole. In these or otherembodiments, each A block has an number average molecular weight of lessthan 250 kg/mole, in other embodiments less than 175 kg/mole, and inother embodiments less than 125 kg/mole.

Exemplary styrene block copolymers include styrene-butadiene-styreneblock copolymer, hydrogenated styrene-butadiene-styrene block copolymer(which may also be referred to as styrene-ethylene/butene-styrene blockcopolymer), styrene-isoprene-styrene block copolymer, and hydrogenatedstyrene-isoprene-styrene block copolymer (which may also be referred toas styrene-ethylene/propylene-styrene block copolymer). For ease ofdescription, these polymers may be referred to, respectively, as S-B-Sblock copolymer, S-E/B-S block copolymer, S-I-S block copolymer, andS-E/P-S block copolymer.

The polystyrene block copolymer-based, pressure-sensitive adhesivecompositions used in this invention may also include a modifying resin.In one or more embodiments, modifying resins include end-block modifyingresins and/or mid-block modifying resins. As is known in the art,end-block modifying resins include those resins that modify and/orreinforce the styrene blocks of the block copolymer. It is believed thatthese end-block modifying resins form pseudo cross links between polymerchains. In one or more embodiments, these end-block resins arecharacterized by a ring and ball softening point of at least 90° C., inother embodiments at least 100° C., in other embodiments at least 110°C., in other embodiments at least 120° C., in other embodiments at least140° C., and in other embodiments at least 160° C. Exemplary end-blockmodifying resins include coumarone-indene resins, poly-a-methylstyreneresins, polystyrene resins, vinyl toluene-α-methylstyrene copolymerresins, and polyindene resins. In these or other embodiments, mid-blockmodifying resins are employed. As is known in the art, mid-blockmodifying resins include those resins that modify and/or reinforce thediene blocks of the block copolymer. It is believed that these mid-blockmodifying resins form pseudo cross links between polymer chains. In oneor more embodiments, mid-block modifying resins include aliphatic resinssuch as pentene-type resins, terpene resins, and cycloaliphatic resins.

Exemplary polyphenylene ether resins, such as polyphenylene oxide, mayalso be used. In one or more embodiments, these resins are characterizedby an intrinsic viscosity of less than 0.4 dl/g, in other embodimentsless than 0.35 dl/g, and in other embodiments less than 0.2 dl/g, whenmeasured in solution in chloroform at 25° C. Useful polyphenylene etherresins are described in U.S. Pat. Nos. 3,306,874 and 3,257,375, whichare incorporated herein by reference.

In one or more embodiments, the pressure-sensitive adhesives based uponstyrene block copolymers may also include an adhesive promoting resin ortackifying resin. In one or more embodiments, a hydrogenated tackifyingresin is employed. These resins include, but are not limited to,petroleum resins, synthetic polyterpenes, resin esters and naturalterpenes, and combinations thereof. In certain embodiments, the resinmodifiers soften or become liquid at temperatures of about 40° C. toabout 150° C. In certain embodiments, the resin modifiers have numberaverage molecular weights, as measured by vapor phase osmometry, belowthat of the polymeric material included in the polymeric film. Incertain embodiments, the number average molecular weights of the resinmodifiers are less than about 5,000. In other embodiments, the numberaverage molecular weights of the resin modifiers are less than about1,000. In additional embodiments, the number average molecular weightsof the resin modifiers are from about 500 to about 1000.

In certain embodiments, the resin modifiers have ring and ball softeningpoint of about 20° C. to about 160° C. In additional embodiments, resinmodifiers have ring and ball softening points of about 40° C. to about160° C. In still other embodiments, resin modifiers have ring and ballsoftening points of about 50° C. to about 160° C.

Various types of natural and synthetic resins, alone or in admixturewith each other, may be used be selected as the resin modifier. Suitableresins include, but are not limited to, natural rosins and rosin esters,hydrogenated rosins and hydrogenated rosin esters, coumarone-indeneresins, petroleum resins, polyterpene resins, and terpene-phenolicresins. Specific examples of suitable petroleum resins include, but arenot limited to, aliphatic hydrocarbon resins, hydrogenated aliphatichydrocarbon resins, mixed aliphatic and aromatic hydrocarbon resins,hydrogenated mixed aliphatic and aromatic hydrocarbon resins,cycloaliphatic hydrocarbon resins, hydrogenated cycloaliphatic resins,mixed cycloaliphatic and aromatic hydrocarbon resins, hydrogenated mixedcycloaliphatic and aromatic hydrocarbon resins, aromatic hydrocarbonresins, substituted aromatic hydrocarbons, and hydrogenated aromatichydrocarbon resins. As used herein, “hydrogenated” includes fully,substantially and at least partially hydrogenated resins. Suitablearomatic resins include aromatic modified aliphatic resins, aromaticmodified cycloaliphatic resin, and hydrogenated aromatic hydrocarbonresins. Any of the above resins may be grafted with an unsaturated esteror anhydride to provide enhanced properties to the resin. For additionaldescription of resin modifiers, reference can be made to technicalliterature, e.g., Hydrocarbon Resins, Kirk-Othmer, Encyclopedia ofChemical Technology, 4th Ed. v. 13, pp. 717-743 (J. Wiley & Sons, 1995).

In one or more embodiments, the tackifier resins include phenol-basedresins. Included among the phenol-based resins are phenolic resins.These resins may include reactive phenol resins (also referred to asfunctionalized phenol resins), as well as unreactive resins. In one ormore embodiments, the phenolic resin is a resole resin, which can bemade by the condensation of alkyl, substituted phenols, or unsubstitutedphenols with aldehydes such as formaldehyde in an alkaline medium or bycondensation of bi-functional phenoldialcohols. In one or moreembodiments, this condensation reaction occurs in the excess or molarequivalent of formaldehyde. In other embodiments, the phenolic resin maybe formed by an acid-catalyzed reaction.

In one or more embodiments, the tackifier resin is a polybutene polymeror oligomer. In particular embodiments, polybutene oils are employed.Useful polybutene oils include high-viscosity oils that may becharacterized by a viscosity at 100° C. of at least 80 cst, in otherembodiments at least 100 cst, or in other embodiments at least 120 cstup to, for example, about 700 or 800 cst. In these or other embodiments,the high viscosity polybutene oils may be characterized by a molecularweight of at least 1000 g/mole, in other embodiments at least 1200g/mole, or in other embodiments at least 1300 g/mole up to, for example,1400 or 1500 g/mole. An exemplary high-viscosity polybutene oil isavailable under the tradename Indapol H300 (Ineos) or PB32 (Soltex).

In particular embodiments, the tackifying resins include hydrogenatedrosins, esters of rosins, polyterpenes, terpene phenol resins, andpolymerized mixed olefins. In one or more embodiments, these resins areliquids at room temperature.

Expandable Graphite

Expandable graphite may also be referred to as expandable flakegraphite, intumescent flake graphite, or expandable flake; and, for thepurposes herein, these terms may be used interchangeably.

In one or more embodiments, expandable graphite includes intercalatedgraphite in which an intercallant material is included between thegraphite layers of graphite crystal or particle. Examples ofintercallant materials include halogens, alkali metals, sulfates,nitrates, various organic acids, aluminum chlorides, ferric chlorides,other metal halides, arsenic sulfides, and thallium sulfides. In certainembodiments of the present invention, the expandable graphite includesnon-halogenated intercallant materials. In certain embodiments, theexpandable graphite includes sulfate intercallants, also referred to asgraphite bisulfate. As is known in the art, bisulfate intercalation isachieved by treating highly crystalline natural flake graphite with amixture of sulfuric acid and other oxidizing agents which act tocatalyze the sulfate intercalation.

Commercially available examples of expandable graphite include HPMSExpandable Graphite (HP Materials Solutions, Inc., Woodland Hills,Calif.) and Expandable Graphite Grades 1721 (Asbury Carbons, Asbury,N.J.). Other commercial grades contemplated as useful in the presentinvention include 1722, 3393, 3577, 3626, and 1722HT (Asbury Carbons,Asbury, N.J.).

In one or more embodiments, the expandable graphite may be characterizedas having a mean or average size in the range from about 30 μm to about1.5 mm, in other embodiments from about 50 μm to about 1.0 mm, and inother embodiments from about 180 to about 850 μm. In certainembodiments, the expandable graphite may be characterized as having amean or average size of at least 30 μm, in other embodiments at least 44μm, in other embodiments at least 180 μm, and in other embodiments atleast 300 μm. In one or more embodiments, expandable graphite may becharacterized as having a mean or average size of at most 1.5 mm, inother embodiments at most 1.0 mm, in other embodiments at most 850 μm,in other embodiments at most 600 μm, in yet other embodiments at most500 μm, and in still other embodiments at most 400 μm. Useful expandablegraphite includes Graphite Grade #1721 (Asbury Carbons), which has anominal size of greater than 300 μm.

In one or more embodiments, the expandable graphite may be characterizedas having a median size in the range from about 30 μm to about 1.5 mm,in other embodiments from about 50 μm to about 1.0 mm, and in otherembodiments from about 180 to about 850 μm. In certain embodiments, theexpandable graphite may be characterized as having a median size of atleast 30 μm, in other embodiments at least 44 μm, in other embodimentsat least 180 μm, and in other embodiments at least 300 μm. In one ormore embodiments, expandable graphite may be characterized as having amedian size of at most 1.5 mm, in other embodiments at most 1.0 mm, inother embodiments at most 850 μm, in other embodiments at most 600 μm,in yet other embodiments at most 500 μm, and in still other embodimentsat most 400 μm. Useful expandable graphite includes Graphite Grade #1721(Asbury Carbons), which has a nominal size of greater than 300 μm.

In one or more embodiments of the present invention, the expandablegraphite may be characterized as having a nominal particle size of 20×50(US sieve). US sieve 20 has an opening equivalent to 0.841 mm and USsieve 50 has an opening equivalent to 0.297 mm. Therefore, a nominalparticle size of 20×50 indicates the graphite particles are at least0.297 mm and at most 0.841 mm.

In one or more embodiments, the expandable graphite may be characterizedas having a carbon content in the range from about 70% to about 99%. Incertain embodiments, the expandable graphite may be characterized ashaving a carbon content of at least 80%, in other embodiments at least85%, in other embodiments at least 90%, in yet other embodiments atleast 95%, in other embodiments at least 98%, and in still otherembodiments at least 99% carbon.

In one or more embodiments, the expandable graphite may be characterizedas having a sulfur content in the range from about 0% to about 8%, inother embodiments from about 2.6% to about 5.0%, and in otherembodiments from about 3.0% to about 3.5%. In certain embodiments, theexpandable graphite may be characterized as having a sulfur content ofat least 0%, in other embodiments at least 2.6%, in other embodiments atleast 2.9%, in other embodiments at least 3.2%, and in other embodiments3.5%. In certain embodiments, the expandable graphite may becharacterized as having a sulfur content of at most 8%, in otherembodiments at most 5%, in other embodiments at most 3.5%.

In one or more embodiments, the expandable graphite may be characterizedas having an expansion ratio (cc/g) in the range from about 10:1 toabout 500:1, in other embodiments at least 20:1 to about 450:1, in otherembodiments at least 30:1 to about 400:1, in other embodiments fromabout 50:1 to about 350:1. In certain embodiments, the expandablegraphite may be characterized as having an expansion ratio (cc/g) of atleast 10:1, in other embodiments at least 20:1, in other embodiments atleast 30:1, in other embodiments at least 40:1, in other embodiments atleast 50:1, in other embodiments at least 60:1, in other embodiments atleast 90:1, in other embodiments at least 160:1, in other embodiments atleast 210:1, in other embodiments at least 220:1, in other embodimentsat least 230:1, in other embodiments at least 270:1, in otherembodiments at least 290:1, and in yet other embodiments at least 300:1.In certain embodiments, the expandable graphite may be characterized ashaving an expansion ratio (cc/g) of at most 350:1, and in yet otherembodiments at most 300:1.

In one or more embodiments, the expandable graphite, as it exists withthe asphaltic component of the asphaltic sheet of the present invention,is partially expanded. In one or more embodiments, the expandablegraphite is not expanded, however, to a deleterious degree, whichincludes that amount or more of expansion that will deleteriously theability to form the sheet product and the ability of the graphite toserve as flame retardant at desirable levels, which include those levelsthat allow proper formation of the sheet. In one or more embodiments,the expandable graphite is expanded to at most 100%, in otherembodiments at most 50%, in other embodiments at most 40%, in otherembodiments at most 30%, in other embodiments at most 20%, and in otherembodiments at most 10% beyond its original unexpanded size.

In one or more embodiments, the expandable graphite may be characterizedas having a pH in the range from about 1 to about 10; in otherembodiments from about 1 to about 6; and in yet other embodiments fromabout 5 to about 10. In certain embodiments, the expandable graphite maybe characterized as having a pH in the range from about 4 to about 7. Inone or more embodiments, the expandable graphite may be characterized ashaving a pH of at least 1, in other embodiments at least 4, and in otherembodiments at least 5. In certain embodiments, the expandable graphitemay be characterized as having a pH of at most 10, in other embodimentsat most 7, and in other embodiments at most 6.

In one or more embodiments, the expandable graphite may be characterizedby an onset temperature ranging from about 100° C. to about 280° C.; inother embodiments from about 160° C. to about 225° C.; and in otherembodiments from about 180° C. to about 200° C. In one or moreembodiments, the expandable graphite may be characterized by an onsettemperature of at least 100° C., in other embodiments at least 130° C.,in other embodiments at least 160° C., and in other embodiments at least180° C. In one or more embodiments, the expandable graphite may becharacterized by an onset temperature of at most 250° C., in otherembodiments at most 225° C., and in other embodiments at most 200° C.Onset temperature may also be interchangeably referred to as expansiontemperature; it may also be referred to as the temperature at whichexpansion of the graphite starts.

Complementary Flame Retardants

As mentioned above, the expandable graphite may be used in conjunctionwith a complementary flame retardant. In other words, the complementaryflame retardants are dispersed, along with the expandable graphite,throughout the matrix of the pressure-sensitive adhesive composition.These flame retardants may include any compound that increases the burnresistivity, particularly flame spread such as tested by UL 94 and/or UL790, in the polymeric compositions of the present invention. Generally,useful flame retardants include those that operate by forming achar-layer across the surface of a specimen when exposed to a flame.Other flame retardants include those that operate by releasing waterupon thermal decomposition of the flame retardant compound. Useful flameretardants may also be categorized as halogenated flame retardants ornon-halogenated flame retardants.

Exemplary non-halogenated flame retardants include magnesium hydroxide,aluminum trihydrate, zinc borate, ammonium polyphosphate, melaminepolyphosphate, and antimony oxide (Sb₂O₃). Magnesium hydroxide (Mg(OH)₂)is commercially available under the tradename Vertex™ 60, ammoniumpolyphosphate is commercially available under the tradename Exolite™ AP760 (Clarian), which is sold together as a polyol masterbatch, melaminepolyphosphate is available under the tradename Budit™ 3141 (Budenheim),and antimony oxide (Sb₂O₃) is commercially available under the tradenameFireshield™.

Examples of other complementary calcium borate, magnesium hydroxide,basic magnesium carbonate, aluminum trihydrate, zinc borate, gypsum, andmixtures thereof. In these or other embodiments, the complementary flameretardant includes colemanite, which is a borate mineral that isbelieved to include about 50-80% calcium borate.

Amounts

In one or more embodiments, the pressure-sensitive adhesive compositionof the present invention includes at least 1, in other embodiments atleast 2, in other embodiments at least 3, and in other embodiments atleast 5 percent by weight expandable graphite based upon the entireweight of pressure-sensitive adhesive composition. In these or otherembodiments, the pressure-sensitive adhesive composition of the presentinvention includes at most 35, in other embodiments at most 15, and inother embodiments at most 12 percent by weight expandable graphite basedupon the entire weight of the pressure-sensitive adhesive composition.In one or more embodiments, the pressure-sensitive adhesive compositionof the present invention includes from about 1 to about 20, in otherembodiments from about 2 to about 15, and in other embodiments fromabout 3 to about 12 percent by weight expandable graphite based on theentire weight of the pressure-sensitive adhesive composition.

In one or more embodiments, the pressure-sensitive adhesive compositionof the present invention includes at least 1, in other embodiments atleast 3, in other embodiments at least 5, and in other embodiments atleast 7 percent by weight complementary flame retardant based upon theentire weight of pressure-sensitive adhesive composition. In these orother embodiments, the pressure-sensitive adhesive composition of thepresent invention includes at most 30, in other embodiments at most 25,and in other embodiments at most 15 percent by weight complementaryflame retardant based upon the entire weight of the pressure-sensitiveadhesive composition. In one or more embodiments, the pressure-sensitiveadhesive composition of the present invention includes from about 1 toabout 95, in other embodiments from about 3 to about 20, and in otherembodiments from about 5 to about 15 percent by weight complementaryflame retardant based on the entire weight of the pressure-sensitiveadhesive composition.

Preparation of Pressure-Sensitive Adhesive Composition

In one or more embodiments, the pressure-sensitive adhesive compositionmay generally be prepared by using conventional techniques for formingthese compositions. In general, and as those skilled in the artappreciate, the various constituents of the adhesive compositions may beintroduced and mixed at elevated temperatures. For example, theconstituents may be mixed at temperatures of at least 260° F. (127° C.),in other embodiments at least 300° F. (149° C.), and in otherembodiments at least 320° F. (160° C.). In these or other embodiments,the constituents may be introduced and mixed at temperatures below 400°F. (204° C.), in these or other embodiments below 390° F. (199° C.), andin other embodiments below 380° F. (193° C.).

In one or more embodiments, the pressure-sensitive adhesive compositionsof the present invention are prepared by employing a two-stage mixingprocess. For example, all of the constituents of the adhesivecomposition, except for the expandable graphite, are first mixed. Bymixing the constituents excluding the expandable graphite in a firstmixing step, the temperature at which the constituents may be mixed canbe increased to achieve greater dispersion and/or mixing of theconstituents without triggering expansion of the expandable graphite.Once these constituents are mixed at a higher temperature (which willform a premixture), the composition can be cooled and the expandablegraphite can then be introduced to the premixture and further mixing maytake place to disperse the expandable graphite within thepressure-sensitive adhesive composition at an appropriate temperature.

In other embodiments, the adhesive composition is devoid orsubstantially devoid of expandable graphite. In these embodiments, theexpandable graphite is incorporated into the adhesive sheet downstream.For example, the expandable graphite can be dropped onto a sheet ofadhesive.

In yet other embodiments, the expandable graphite is included in theadhesive composition prior to formation of the solid pressure sensitiveadhesive body, and the expandable graphite may also be incorporated intothe adhesive downstream (e.g. by dropping the expandable graphite onto asheet of adhesive).

In one or more embodiments, expandable graphite particles are dropped onto a sheet of molten adhesive, wherein the adhesive may or may notinclude expandable graphite. These particles are dropped at a rate andamount to create at least a partial layer of expandable graphiteparticles adjacent to the adhesive sheet. In one or more embodiments,the act of dropping the expandable graphite particles on to an adhesivesheet may at least partially embed some of the graphite particles in tothe adhesive such that the adhesive serves as a binder to hold thegraphite particles in place. In these or other embodiments, one or moreof the plurality of expandable graphite particles are adhered to thesurface of the adhesive sheet by way of the adhesive properties of theadhesive material. In one or more embodiments, the step of dropping theexpandable graphite creates a concentration gradient of the expandablegraphite and the adhesive.

In one or more embodiments, the process of dropping expandable graphiteparticles on to an adhesive sheet takes place after the adhesive sheetis prepared and prior to a substantial cooling of the adhesive materialso as to take advantage of the adhesive properties of the adhesive. Inone or more embodiments, at least a portion of the expandable graphiteparticles are dropped on or otherwise applied to an adhesive sheetwithin 15 seconds, in other embodiments within 10 seconds, and in otherembodiments within 5 seconds of the adhesive sheet being prepared. Inone or more embodiments, the expandable graphite is dropped on theadhesive sheet prior to solidification of the adhesive material (e.g.prior to the adhesive sheet cooling to a temperature below about 85° C.

In one or more embodiments, the expandable graphite particles areapplied to the surface of an adhesive sheet using a multi-stage process.For example, a multi-stage process may include multiple drops ofgraphite particles. In certain embodiments, the various stages or dropscan be configured to achieve certain characteristics. For example,different sized expandable graphite particles can be dropped atdifferent stages in order to achieve desirable coverage of the surfaceof the adhesive sheet.

In one or more embodiments, additional adhesive material applied to thesheet after application of the expandable graphite (e.g. after droppingthe expandable graphite onto the sheet, which can form the layer ofexpandable graphite or concentrated region of expandable graphite). Thismay take place by using curtain coating or roll coating techniques. Inother embodiments, the expandable graphite is dropped onto the adhesivesheet prior to the sheet being calendered or sized within a nip roll. Asa result, then the sheet is calendered or sized within a nip roll, theexcess adhesive material at the nip roll will serve to form a layer (orskin) of adhesive material over the layer of expandable graphite.

In certain embodiments, a polymeric layer is applied to the adhesivesheet after application of the expandable graphite particles. Forexample, following one or more drops or applications of the expandablegraphite particles to a surface of the adhesive sheet, a polymeric filmmay be applied over the expandable graphite particles. In one or moreembodiments, this may facilitate subsequent calendaring of the adhesivesheet carrying the expandable graphite particles. In other embodiments,the layer of expandable graphite particles may be modified by theapplication of a release agent, such as sand, silica, or talc, over theexpandable graphite particles. The presence of release agents may, likethe polymeric film, facilitate subsequent calendaring of the adhesivesheet.

Structure of Adhesive Layer

In one or more embodiments, the structure of the adhesive layer relativeto the expandable graphite can be modified. In one or more embodiments,the expandable graphite is dispersed throughout the adhesive. Dependingon mixing, the dispersion of the expandable graphite may be generallyhomogeneous. In other embodiments, the degree of dispersion may bereferred to as random.

In other embodiments, the expandable graphite may be in the form of alayer or concentrated region within or adjacent to the adhesive. Forexample, and with reference to FIG. 3, adhesive layer 54 includes one ormore layers 60 of particles of expandable graphite. These particles maybe held in place by a matrix of adhesive composition present within atleast a portion of adhesive layer 54. In these or other embodiments, theexpandable graphite is held in place by being adhered to the surface ofsheet 12. In one or more embodiments, adhesive layer 54 may also includeexpandable graphite dispersed therein. In other words, the adhesivelayer includes both a layer or region 60 having a high concentration ofexpandable graphite and it has expandable graphite dispersed throughoutthe matrix of the adhesive. While a continuous layer or region (e.g.layer 54) is believed to be advantageous, it is also contemplated thatthe adhesive layer 54 can include multiple discreet regions of theexpandable graphite, such as may exist in a pattern where the expandablegraphite is applied on the top of the asphaltic sheet in rows or stripsin the machine direction of the sheet.

In one or more embodiments, the thickness of the layer of expandablegraphite may be at least 10 μm, in other embodiments at least 20 μm, inother embodiments at least 30 μm, in other embodiments at least 75 μm,and in other embodiments at least 100 μm. In these or other embodiments,the thickness of the layer of expandable graphite may be at most 3 mm,in other embodiments at most 2 mm, and in other embodiments at most 1mm. In one or more embodiments, the thickness of the layer of expandablegraphite may be from about 10 μm to about 3 mm, in other embodimentsfrom about 75 μm to about 2 mm, and in other embodiments from about 100μm to about 1 mm.

In one or more embodiments, the layer of expandable graphite particlesmay be covered by a layer of adhesive. Stated another way, the layer orregion of concentrated expandable graphite may be embedded within theadhesive material.

In one or more embodiments, the thickness of the adhesive layer over thelayer of expandable graphite particles may be at least 2 μm, in otherembodiments at least 5 μm, and in other embodiments at least 20 μm. Inthese or other embodiments, the thickness of the adhesive layer over thelayer of expandable graphite particles may be at most 1 mm, in otherembodiments at most 0.5 mm, in other embodiments at most 0.25 mm, inother embodiments at most 0.1 mm, and in other embodiments at most 0.050mm. In one or more embodiments, the thickness of the adhesive layer overthe layer of expandable graphite particles may be from about 1 μm toabout 3 mm, in other embodiments from about 2 μm to about 0.5 mm, and inother embodiments from about 5 μm to about 0.050 mm.

In one or more embodiments, as shown in FIGS. 1 through 4, the adhesivelayer 14 (also 34, 54, and 74) may include a planar region within themembrane, moisture barrier, underlayment, or tape that includes a higherconcentration of expandable graphite relative to any other region of thearticle. Thus, layer 14 may include a continuous layer of expandablegraphite having a variable or relatively constant thickness across themembrane, moisture barrier, underlayment, or tape. Or, in otherembodiments, the expandable graphite may be discontinuous throughout theregion so long as the concentration of expandable graphite within theregion is higher than in other areas or regions of membrane, moisturebarrier, underlayment, or tape. In one or more embodiments, thediscontinuity of the expandable graphite within the layer 14 (also 34,54, and 74) may result from the adhesive composition which may form amatrix in which the expandable graphite is at least partially dispersedwithin this region or layer. While the expandable graphite may bedispersed uniformly within the adhesive layer, it should also beappreciated that the concentration of the expandable graphite may not beconstant within this layer. Indeed, as will be appreciated from thedescription of how to fabricate the articles of the embodiments herein,a concentration gradient may exist whereby the concentration of theexpandable graphite moves from a region of maximum concentration to aregion of decreased concentration.

As shown in expanded view in FIG. 2, the concentration of expandablegraphite 42 approximately equidistant from planar surfaces 38 and 40within layer 34 is the highest, which corresponds to a minimum inadhesive composition concentration. On the other hand, the concentrationof expandable graphite 42 proximate to planar surfaces 38 and 40 are ata minimum relative to the concentration of expandable graphite withinlayer 34.

As shown in expanded view in FIG. 3, the concentration of expandablegraphite 62 approximately furthest from planar surface 58 within layer54 is the highest, which corresponds to a minimum in adhesivecomposition concentration. On the other hand, the concentration ofexpandable graphite 62 proximate to planar surface 58 is at a minimumrelative to the concentration of expandable graphite within layer 54.

INDUSTRIAL APPLICABILITY

In one or more embodiments, the pressure-sensitive adhesive compositionsof the present invention, which include expandable graphite, areadvantageously employed in combination with construction materials. As aresult, the pressure-sensitive adhesive compositions not only provide ameans by which construction materials can be adhered to a substrate, butthey also provide the construction materials with increased flame and/orfire resistance.

Fully Adhered Roofing System

In one or more embodiments, the construction material is a roofingmembrane to which the pressure-sensitive adhesive composition isadhered, thereby providing a mechanism by which the membrane can beadhered to another building material, such as an adjacent membrane or asubstrate. In particular embodiments, the pressure-sensitive adhesivecomposition of the present invention is applied to a surface of themembrane in a manner that will allow the membrane to be installed as afully-adhered roofing system. Those skilled in the art appreciate thatfully-adhered roofing systems include those systems wherein the membraneis adhered to the roof substrate substantially across the entire planarsurface of the membrane contacting the substrate.

With reference to FIG. 1, membrane 11 includes a water-impermeable sheet12, adhesive layer 14, and optional release liner 16. Adhesive layer 14is adhered to sheet 12 across a first planar surface 18 of sheet 12 byapplication of the pressure-sensitive adhesive composition to the sheet.For example, and as will be described in greater detail below, where thepressure-sensitive adhesive composition is a hot-melt, hot applicationof the pressure-sensitive adhesive composition to the membrane formslayer 14, which is adhered to sheet 12. Release liner 16 is applied toadhesive layer 14 on a planar surface 20 of adhesive layer 14 oppositesheet 12.

In one or more embodiments, the thickness of adhesive layer 14 on sheet12 is from about 2 mils (0.05 mm) to about 90 mils (2.3 mm), in otherembodiments from about 3 mils (0.08 mm) to about 50 mils (1.3 mm), andin other embodiments from about 5 mils (0.13 mm) to about 50 mils (1.3mm) in thickness.

In one or more embodiments, water-impermeable sheet 12, which may alsobe referred to as membrane 12, may be a thermoset material. In otherembodiments the membrane may be a thermoformable material. In one ormore embodiments, the membrane may be EPDM based. In other embodiments,the membrane may be plastic based. In these or other embodiments, themembrane may be flexible and capable of being rolled up for shipment. Inthese or other embodiments, the membrane may include fiberreinforcement, such as a scrim. In one or more embodiments, the membraneincludes EPDM membranes including those that meet the specifications ofthe ASTM D-4637. In other embodiments, the membrane includesthermoplastic membranes including those that meet the specifications ofASTM D-6878-03.

In one or more embodiments, the thickness sheet or membrane 12 is fromabout 20 mils (0.51 mm) to about 100 mils (2.54 mm), in otherembodiments from about 30 mils (0.76 mm) to about 90 mils (2.3 mm), andin other embodiments from about 40 mils (1.0 mm) to about 80 mils (2.0mm) in thickness.

Referring again to FIG. 1, in one or more embodiments, optional releaseliner 16 is positioned over adhesive layer 14 to prevent contaminantsfrom contacting and collecting on adhesive layer 14. The tackiness ofadhesive layer 14 holds release liner 16 in place. Release liner 16 mayinclude a thin film or coating to which the adhesive may form atemporary bond. However, this bond can be readily broken by applyingminimal tension. Release liner 16 may advantageously provide protectionto adhesive layer 14 during storage or shipment, and may remain in placeuntil a roof mechanic removes it during rooftop membrane installationprior to installation of the membrane. In one or more embodiments,release liner 16 may be between approximately 1 mil (0.02 mm) and 9 mils(0.23 mm) in thickness, in other embodiments between approximately 1 mil(0.02 mm) and 7 mils (0.18 mm) in thickness, in still other embodimentsbetween approximately 2 mils (0.05 mm) and 6 mils (0.15 mm) inthickness, and in yet other embodiments between approximately 2 mils(0.05 mm) and 4 mils (0.10 mm) in thickness.

In one or more embodiments, release liner 16 may include a paper orcellulosic structure coated with a polymeric coating. In otherembodiments, release liner 16 may include a homogeneous polymericstructure; for example, release liner 16 may include a polyester orpolyolefin film. Suitable materials for release liner 16 includepolypropylene, polyester, high-density polyethylene, medium-densitypolyethylene, low-density polyethylene, polystyrene or high-impactpolystyrene. Such polymeric materials offer a number of advantageousproperties, including high moisture resistance, good resistance totemperature fluctuations during processing and storage, high tearresistance. In one or more embodiments, these release liners may also beprovided with anti-static surface coatings. In addition to the abovepolymeric release liner materials, release liner 16 may also be made ofkraft paper.

Thus membrane assembly 11 includes a factory-applied adhesive and thatis covered and protected by an optional release liner. By applying thepressure-sensitive adhesive in a controlled factory environment,contamination is minimized. Further, factory application ofpressure-sensitive adhesive 14 allows for additional safety precautionsduring the “flash-off” period. Specifically, proper ventilation may beensured so that the exposure of workers to harmful fumes is prevented.Further, this method allows metered application of the primer andenables more effective and standardized scrubbing and preparation of themembrane.

In one or more embodiments, the pressure-sensitive adhesive can beapplied to the membrane in the form of a hot-melt adhesive. As thoseskilled in the art appreciate, the pressure-sensitive adhesivecomposition, in the form of a hot melt, can be heated above its meltpoint and applied to the membrane in the form of a thin-film extrudate.

In other embodiments, the pressure-sensitive adhesive is applied to themembrane in the form of a liquid that is permitted to dry and/or cure tothereby leave a solids residue of the pressure sensitive adhesive.

Moisture Barrier

In yet another embodiment, the pressure-sensitive adhesive is applied toa substrate to form a moisture, vapor and/or air barrier having improvedflame-resistant and/or fire-resistant properties. As those skilled inthe art may appreciate, these moisture barriers may be employed incavity wall systems to provide both moisture and vapor barrierproperties.

In one or more embodiments, the substrate to which the adhesive isapplied may have a thickness of between approximately 1 mil (0.03 mm)and 20 mils (0.51 mm) in thickness, in other embodiments betweenapproximately 2 mils (0.05 mm) and 15 mils (0.38 mm) in thickness, andin still other embodiments between approximately 3 and 10 mils inthickness.

In one or more embodiments, the thickness of the adhesive layer onpolymeric sheet substrate may from about 2 to about 90 mils, in otherembodiments from about 3 mils (0.08 mm) to about 50 mils (1.3 mm), andin other embodiments from about 5 mils (0.13 mm) to about 50 mils (1.3mm) in thickness.

In one or more embodiments, the substrate to which thepressure-sensitive adhesive can be applied is polymeric sheet or film(e.g. polymeric extrudate) that includes or is prepared from, forexample, polyethylene, polypropylene, copolymers of ethylene andpropylene, and polyester. In or more embodiments, the polymeric sheet orfilm is a polypropylene sheet. In other embodiments, the substrate towhich the adhesive composition is applied is a foil metal such asaluminum foil. In one or more embodiments, these foils may includefabric reinforcement. In still other embodiments, the substrate to whichthe adhesive composition is applied is a fabric such as a syntheticfiber (e.g. polyolefin or polyester non-woven fiber fabric). In yetother embodiments, the substrate to which the adhesive composition isapplied is a paper-reinforced foil.

With reference to FIG. 2, moisture barrier 30 includes awater-impermeable sheet 32, adhesive layer 34, and optional releaseliner 36. Adhesive layer 34 is adhered to sheet 32 across a first planarsurface 38 of sheet 32 by application of the pressure-sensitive adhesivecomposition to the sheet. Expandable graphite particles 42 are dispersedwithin the adhesive layer 34. Release liner 36 is applied to adhesivelayer 34 on a planar surface 40 of adhesive layer 34 oppositewater-impermeable sheet 32. The expandable graphite may be uniformly ornon-uniformly dispersed. It will further be appreciated that theexpandable graphite may be dispersed with a concentration gradient asdepicted in FIG. 2 wherein the highest concentration of expandablegraphite is positioned approximately equidistant from planar surfaces 38and 40 within adhesive layer 34, or alternatively the expandablegraphite may be dispersed with a concentration gradient as depicted inFIG. 3 wherein the highest concentration of expandable graphite ispositioned furthest from planar surface 58 within layer adhesive 54, ora combination of gradients therein.

Underlayment

In still other embodiments, the pressure-sensitive adhesive is appliedto a substrate to form an underlayment having improved flame-resistantand/or fire-resistant properties. As those skilled in the art mayappreciate, these underlayments may be employed in a variety of roofingsystems, such as metal roof systems, to provide increased flame and/orfire resistance. In one or more embodiments, the underlayment preparedaccording to one or more embodiments of the present invention meet thestandards of ASTM D1970.

In one or more embodiments, the thickness of the adhesive layer appliedto the substrate of the underlayment may be from about 2 mils (0.05 mm)to about 90 mils (2.3 mm), in other embodiments from about 3 mils (0.07mm) to about 50 mils (1.3 mm), and in other embodiments from about 5mils (0.13 mm) to about 50 mils (1.3 mm) in thickness.

In one or more embodiments, the substrate to which the adhesive isapplied to form the underlayment may have a thickness of betweenapproximately 1 and 20 mils (0.51 mm) in thickness, in other embodimentsbetween approximately 2 mils (0.05 mm) and 15 mils (0.39 mm) inthickness, and in still other embodiments between approximately 3 mils(0.07 mm) and 10 mils (0.25 mm) in thickness.

In one or more embodiments, the substrate to which thepressure-sensitive adhesive can be applied to form the underlayment maybe polymeric sheet or film (e.g. polymeric extrudate) that includes oris prepared from, for example, polyethylene, polypropylene, copolymersof ethylene and propylene, and polyester. In or more embodiments, thepolymeric sheet or film is a polypropylene sheet. In particularembodiments, the polymeric substrate is surface textured to provide asurface that is not smooth. In other embodiments, the substrate to whichthe adhesive composition is applied to form an underlayment is a foilmetal such as aluminum foil. In one or more embodiments, these foils mayinclude fabric reinforcement. In still other embodiments, the substrateto which the adhesive composition is applied to form an underlayment isa fabric such as a synthetic fiber (e.g. polyolefin or polyesternon-woven fiber fabric).

With reference to FIG. 3, underlayment 50 includes a water-impermeablesheet 52, adhesive layer 54, and optional release liner 56. Adhesivelayer 54 is adhered to sheet 52 across a first planar surface 58 ofsheet 52 by application of the pressure-sensitive adhesive compositionto the sheet. Expandable graphite particles 62 are dispersed within theadhesive layer 54. Release liner 56 is applied to adhesive layer 54 on aplanar surface 60 of adhesive layer 54 opposite water-impermeable sheet52. The expandable graphite may be uniformly or non-uniformly dispersed.It will further be appreciated that the expandable graphite may bedispersed with a concentration gradient as depicted in FIG. 2 whereinthe highest concentration of expandable graphite is positionedapproximately equidistant from planar surfaces 38 and 40 within adhesivelayer 34, or alternatively the expandable graphite may be dispersed witha concentration gradient as depicted in FIG. 3 wherein the highestconcentration of expandable graphite is positioned furthest from planarsurface 58 within layer adhesive 54, or a combination of gradientstherein.

Tape

In yet other embodiments, the present invention provides apressure-sensitive tape carrying release liners on opposing planarsurfaces of the adhesive body, which may be in the form of a sheet. Thepressure-sensitive adhesive body includes expandable graphite accordingto embodiments of this invention. In one or more embodiments, theexpandable graphite may be dispersed throughout the adhesive body. Inother embodiments, the expandable graphite may be concentrated in alayer or region within the adhesive body. In yet other embodiments, theexpandable graphite may be both dispersed throughout the adhesive bodyand located within a region or body having a concentrated amount ofexpandable graphite.

As with other embodiments of the invention, the pressure-sensitiveadhesive tape includes release liners that may be formed from apolymeric film or a coated paper. The polymeric film may includepolyolefin films, and the coated paper may include kraft paper coatedwith polysiloxanes or fluoropolymers.

An exemplary tape may be described with reference to FIG. 4, whichdepicts tape 70 having planar shaped adhesive body 74, first releaseliner 76, and second release liner 76′. Expandable graphite particles 82are dispersed within the planar shaped adhesive body 74. First releaseliner 76 and second release liner 76′ are removably attached to adhesivebody 74. The expandable graphite may be uniformly or non-uniformlydispersed. It will further be appreciated that the expandable graphitemay be dispersed with a concentration gradient as depicted in FIG. 2wherein the highest concentration of expandable graphite is positionedapproximately equidistant from planar surfaces 38 and 40 within adhesivelayer 34, or alternatively the expandable graphite may be dispersed witha concentration gradient as depicted in FIG. 3 wherein the highestconcentration of expandable graphite is positioned furthest from planarsurface 58 within layer adhesive 54, or a combination of gradientstherein.

Various modifications and alterations that do not depart from the scopeand spirit of this invention will become apparent to those skilled inthe art. This invention is not to be duly limited to the illustrativeembodiments set forth herein.

What is claimed is:
 1. A method of preparing a building material, themethod comprising the steps of: i. providing a polymeric sheet havingfirst and second planar surfaces; ii. dropping expandable graphite on tothe second planar surface of the polymeric sheet; and iii. applying apressure-sensitive adhesive to cover the expandable graphite dropped onthe polymeric sheet.
 2. The method of claim 1 wherein thepressure-sensitive adhesive includes first and second planar surfacesand where the first planar surface of the pressure-sensitive adhesivelayer is removably attached to the second planar surface of thepolymeric sheet.
 3. The method of claim 2 further comprising the step ofapplying a release liner to the second planar surface of thepressure-sensitive adhesive.
 4. The method of claim 1 wherein thepressure-sensitive adhesive layer includes a polystyrene blockcopolymer.
 5. The method of claim 1 wherein the pressure-sensitiveadhesive layer includes butyl rubber.
 6. The method of claim 1 whereinapplying the pressure-sensitive adhesive to the second planar surface ofthe polymeric sheet forms an interface where the pressure-sensitiveadhesive contacts the second planar surface of the polymeric sheet. 7.The method of claim 6 wherein dropping the expandable graphite on thesecond planar surface of the polymeric sheet forms a concentrated regionof the expandable graphite proximate the interface.
 8. The method ofclaim 1 wherein the pressure-sensitive adhesive is an extrudablepressure-sensitive adhesive.
 9. The method of claim 8 further comprisingthe step of applying a release liner to the extruded pressure-sensitiveadhesive.